Flats Mail Class Package of Substrates with Integral Items

ABSTRACT

A package compliant with a postal service flats mail class includes at least one flat package substrate comprising a uniform edge thickness about one of a longitudinal dimension and a shorter dimension and configured to be flexible parallel to the one dimension and adapted to receive an integral item parallel to the one dimension. The package also includes an integral item at least one of interleaved within the substrate and wrapped around the substrate parallel to the one dimension and adapted to provide flexibility to the other of the two dimensions based on the interleaving and the wrapping and provide a uniform edge thickness to the other of the two dimensions. Furthermore, a receiving package is structured to receive and secure together the integral item and the flat package substrate and provide a uniform thickness and the uniform edge dimensions and be flexible about both the two dimensions.

BACKGROUND OF THE INVENTION

The United States Postal Service (USPS) charges lower delivery rates for certain classes of mail and range of weights, such as Flats, which are readily processed by automated sorters, are of uniform shape and of suitable edge rigidity and thus more efficiently stored in containers.

A flat, as commonly known in the postal processing industry, is a large envelope, newsletter, or magazine. To be designated a “flat” in the USPS, a mail piece must have at least one dimension that is greater than six and one-eighth inches high, eleven and one-half inches long, or one-quarter inch thick, with maximum dimensions of twelve inches high, fifteen inches long, and three-quarters inches thick, wherein the length is the dimension parallel to the address as read, and the height is the dimension perpendicular to the length. The maximum weight can range from about thirteen ounces to about fifteen pounds depending on the mail class used, i.e. first-class mail(thirteen ounces), standard mail (less than sixteen ounces), and bound printed matter (fifteen pounds). The physical standards for qualification as a flat are attached as Appendix 1, incorporated herein in its entirety by reference. The present invention teaches means whereby other types of items may be shipped as flats; thus qualifying for lower postage rates.

The mailing standards are to encourage mail preparation that is compatible with improved processing capabilities, such as increased automation of postal processing. Under the NFM mail category, standard mail pieces with parcel-like characteristics, including rigid pieces, are presorted, entered, and processed as parcels, resulting in significantly higher postage costs.

In particular to flats, the mail standards require that flats must be rectangular, flexible, and uniformly thick within a specified variance to accommodate automated processing equipment. Such requirements are implemented by the above-referenced standards for flexibility and uniformity. For example, to pass the flexibility test, the mail package is placed halfway off the edge of a flat surface such that the length is parallel to the edge of a flat surface. Using constant, steady pressure, the mail package is bent at a point one inch from the outer edge, in the center of its length. The mail package is flexible, according to the standards, if it can bend at least one inch vertically without being damaged. If the mail package does not contain a rigid insert, no further testing is required. If the mail package does contain a rigid insert, then the mail package is placed with its length perpendicular to the edge of the flat surface so that the mail package extends five inches off the surface if it is ten inches or longer, or one-half of its length if it is less than ten inches long. Using constant steady pressure, the mail package is bent at a point one inch from the outer edge, in the center of the piece's width. The mail package is then turned around and the test is repeated. The mail package is flexible, according to the standards, if both ends can bend at least one inch vertically without being damaged if it is less than ten inches long, and at least two inches vertically without being damaged if it is ten inches or longer.

Flat-size mail packages must also meet a standard of uniformity to be processed at the lower rate. The mail packages must be uniformly thick so that any bumps, protrusions, or other irregularities do not cause more than one-fourth of an inch variance in thickness. In determining variance in thickness, the outside edges of a mail package (one inch from each edge) is excluded when the contents of the mail package do not extend into those edges. Also, the selvage of any polywrap covering is excluded from the determination. Mail packages containing non-paper contents must secure the non-paper contents to prevent shifting of more than two inches within the mail package if shifting would cause the package to be non-uniform in thickness or would result in the contents bursting out of the mail package.

In addition to meeting the above standards, the mail package must be capable of being readily processed by automated equipment. Internationally, a flexible, uniform mail package is also desirable to reduce postage rates, minimize shifting of articles within the mail package, and/or to allow the mail package to be readily processed using automated equipment.

There remains a need for a mail piece or package that is capable of accommodating various articles, such as books, CDs/DVDs, small apparel, and the like, while meeting the USPS's flexibility and uniformity standards for automated postal processing, such that the mail package can be readily processed by automated equipment. Such a mail package could also be used internationally.

SUMMARY OF THE INVENTION

A package compliant with a postal service flats mail class comprises at least one flat package substrate comprising a uniform edge thickness about one of a longitudinal dimension and a shorter dimension and configured to be flexible parallel to the one dimension and adapted to receive an integral item parallel to the one dimension. The package also includes an integral item at least one of interleaved within the substrate and wrapped around the substrate parallel to the one dimension and adapted to provide flexibility to the other of the two dimensions based on the interleaving and the wrapping and provide a uniform edge thickness to the other of the two dimensions. The package further includes a receiving package structured to receive and secure together the integral item and the flat package substrate and provide a uniform thickness and the uniform edge dimensions and be flexible about both the two dimensions to comply with a postal service flats mail class.

The package may also comprise one of a plurality of CDs (compact discs) and a plurality of DVDs (digital video disks) received in a plurality of slits in the flat package substrate configured to resemble a plurality of fish scales adapted to enable flexibility in a direction of the plurality of slits when the substrate and items are packaged. The integral item wrapped around the substrate parallel to the one dimension is a textile, an article of clothing, a necklace and a bracelet. The flat package substrate further comprises a scalloped edge adapted to receive one of an article of clothing, a textile, a necklace and a bracelet wrapped around the flat package substrate parallel to the one dimension.

A package system compliant with a postal service flats mail class comprises at least one flat package superstrate having a uniform edge thickness about one of a longitudinal dimension and a shorter dimension and configured to be flexible parallel to the one dimension and adapted to receive an integral item parallel to the one dimension. The integral item is at least one of interleaved within the superstrate and received therein parallel to the one dimension and adapted to provide flexibility to the other of the two dimensions based on the interleaving and the receiving therein and provide a uniform edge thickness to the other of the two dimensions.

Other aspects and advantages of embodiments of the disclosure will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrated by way of example of the principles of the disclosure.

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BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top elevational view of the integral Compact Disks/Digital Video Disk (CD/DVD) Items, the flat package substrate with slits and the securing package in accordance with an embodiment of the present disclosure.

FIG. 2 is a top elevational view of a clothing item, the flat package substrate with slits and the securing package in accordance with an embodiment of the present disclosure.

FIG. 3 is a top elevational view of integral items including an article of clothing and CD/DVDs and the securing superstrate in accordance with an embodiment of the present disclosure.

Throughout the description, same reference numbers may be used to identify same or similar elements depicted in multiple embodiments. Although specific embodiments of the invention have been described and illustrated, the invention is not to be limited to the specific forms or arrangements of parts so described and illustrated. The scope of the invention is to be defined by the claims appended hereto and their equivalents.

DETAILED DESCRIPTION

Reference will now be made to exemplary embodiments illustrated in the drawings and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Alterations and further modifications of the inventive features illustrated herein and additional applications of the principles of the inventions as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.

Throughout the present disclosure, the term ‘substrate’ may refer to a layer that underlies something. The term ‘superstrate’ may refer to any layer superimposed on another. The term ‘interleave’ may refer to an insertion, a mix or an alternating of an item or items within a substrate or a superstrate.

A package system is disclosed comprising a means of conforming items and packaging to a postal or mail carrier system of mail classification attributes. For example, shipping items such small apparel, soft cover books, CDs and DVDs as qualifying Flats packages may result in lower delivery charges. The invention provides a method, process and materials enabling certain types of items to be packaged so as to qualify for a desired mail class according to physical and other specified characteristics of the mail class.

This application claims the benefits of all copyright laws and is deemed as copyrighted as of the filing date. All rights reserved.

The disclosure describes a packaging content so as to meet requirements for a mail class of service provided by a third party such as a postal system or package, mail or parcel carrier or delivery services operator. A specific embodiment of the disclosure pertains to enabling qualification for the Flats mail class of the United States Postal Service (USPS) for content currently not packaged and mailed in a manner which meets pertinent requirements. The Flats mail class is often cheaper than currently used mail classes such as media mail, first class or parcel ground for items such as small apparel such as under garments or t-shirts, or CDs, DVDs and videogames and books. The disclosure provides a conforming combination of materials, substrate for apparel, conforming sleeve type for media or apparel, packaging method, packaging process and means for physical attribute conformity and testing including weight, dimensions, flexibility, rigidity and uniformity of edges and package perimeter surfaces.

Small apparel items may be folded around, wrapped around or pressed on a substrate or placed within a sleeve made of material that when packaged with the item and suitable packaging material and method, conforms to a mail class specification. Similarly, CD/DVD/audio books may be placed within a sleeve material that results in similar conformity when packaged with suitable material and method that assures criteria for material play within the package, edge and corner attributes and other criteria are met.

Disclosed are materials, and automated or partially automated processes including a means of inserting and preparing shipped content, one or more per package, involving sleeves, substrates, superstrates or combinations together with external packaging material (or use of the sleeve itself as the package) wherein the resulting package conforms with a package type or mail class criteria.

A t-shirt or CD may be inserted in a semi-rigid yet flexible sleeve and packaged in a poly vinyl bag wherein said bag is manually or through automation treated so as to meet edge, content play, dimension, weight, and other criteria. Packages, sleeves and substrates may be customized in attributes for item types such as apparel or digital content disks.

In one embodiment a small garment may be wrapped around, folded around, pressed on or enclosed within a substrate or sleeve which itself, or within a package such as poly vinyl envelope or bubble envelope, meets the mail class criteria inclusive of weight, dimensions, rigidity, directional flexibility, edge and corner consistency.

In another embodiment, a CD, DVD or audio book with artwork and paper instructions may be inserted in a sleeve with meets the Flats physical attributes for weight, rigidity, dimensions, and when placed inside a package such as poly vinyl envelope, bubble envelope, paper or other packaging media, enables the package as a whole to meet said criteria including uniformity and rigidity yet flexibility of edges and the package as a whole in at least one direction. Similarly, books themselves meeting said criteria when shipped in suitable material wherein edges are tightly wrapped or articulated by automated equipment also meet said criteria are a further embodiment. Packages and sleeves may contain one or more items wherein items or so placed so as to enable package flexibility such as overlapping placement of CD or DVD disks like fish scales enabling flexibility in the desired package direction.

In a further embodiment, a substrate my contain cavities of blisters designed to contain small items such as jewelry, watches, contact lens, medications. A plastic or paper film may be used to further secure such items to the substrate. When the substrate is packaged, as a result of either or both of the attributes of the substrate or package, the package conforms to a mail class standard.

A substrate may be used that enables the package with CDs/DVDs without jewel boxes to meet the flats criteria; which substrate may have pockets into which CDs/DVDs/Game DVDs may be placed which are partially overlapping like fish scales and enable multiple such items to be placed in the same substrate yet enable adequate flexibility parallel with or orthogonal to an orientation of the articles.

FIG. 1 is a top elevational view of the integral Compact Disks/Digital Video Disk (CD/DVD) Items, the flat package substrate with slits and the securing package in accordance with an embodiment of the present disclosure. The block arrows depict the integration of the claimed and described components. Same reference numbers for similar limitations and/or components may be depicted in common with other figures herein.

A disclosed package compliant with a postal service flats mail class includes at least one flat package substrate 10 comprising a uniform edge thickness about one of a longitudinal dimension 15 and a shorter dimension 20 and configured to be flexible parallel to the one dimension and adapted to receive an integral item parallel to the one dimension. The package also includes an integral item(s) 25 at least one of interleaved within the substrate 10 and wrapped around the substrate 10 parallel to the one dimension and adapted to provide flexibility to the other of the two dimensions based on the interleaving and the wrapping combination 30 and provide a uniform edge thickness to the other of the two dimensions. The package further includes a receiving package 35 structured to receive and secure together the integral item and the flat package substrate and provide a uniform thickness and the uniform edge dimensions and be flexible about both the two dimensions to comply with a postal service flats mail class 40.

The disclosed package may also include integral item(s) 25 comprising one of a plurality of CDs (compact discs) and a plurality of DVDs (digital video disks) received in a plurality of slits 45 in the flat package substrate configured to resemble a plurality of partially overlapping fish scales adapted to enable flexibility in a direction of the plurality of slits when the substrate and items are packaged. The slits may be elliptical in some implementations.

The integration of the CD/DVD disks to the substrate improves the flexibility of the combination thereof due to the flexibility of the CD/DVD disks about an axis parallel to the longitudinal dimension 15. A flexibility parallel to the other shorter dimension 20 is based on the flat package substrate 10.

FIG. 2 is a top elevational view of a clothing item, the flat package substrate with slits and the securing package in accordance with an embodiment of the present disclosure. The block arrows depict the integration of the claimed and described components.

In some implementations, the integral item(s) 25 wrapped around the substrate 10 parallel to the one dimension is a textile, an article of clothing, a necklace and a bracelet. The clothing item 25 depicted is a neck tie but could easily be a scarf, a pair of socks, a t-shirt, an undergarment, etc. The flat package substrate 10 further comprises a scalloped edge adapted to receive one of an article of clothing, a textile, a necklace and a bracelet wrapped around the flat package substrate parallel to the one dimension 15 or 20. Same reference numbers for similar limitations and/or components may be depicted in common with other figures herein.

In some implementations, an interior substrate thickness 47 is less than the uniform edge thickness. Additionally, or alternatively, the flat package substrate is a soft cover book being most flexible about an axis parallel to the binding further comprising an external label disposed on the package oriented in a specified direction with respect to one of the flexible axis of the book along its length.

In some implementations, a plurality of flat package substrates are adapted to dispose an article there between and create thickness uniformity and edge uniformity and edge integrity resembling a clam shell design. A soft material envelope-like sleeve structure similar to the receiving package 35 is included to receive and secure together the integral item and the flat package substrate and provide a uniform thickness and the uniform edge dimensions and be flexible about both the two dimensions to comply with a postal service flats mail class. The soft material may comprise one of a sleeve, a sheath, a polybag, an envelope, a shrink wrapping and a vacuum packing. The flat package substrate may be a pharmaceutical blister pack being flexible about a first and a second dimension configured to accommodate pills.

The integration of the clothing article 25 in and out of the slits 45 of the substrate 10 improves the flexibility of the combination thereof due to the flexibility of the clothing article 25 about an axis parallel to the longitudinal dimension 15. A flexibility parallel to the other shorter dimension 20 is based on the flat package substrate 10.

Dimensions detailed herein and in the drawings are intended to be a guide to nominal manufacturing dimensions. The detailed dimensions may vary by plus or minus ten percent taking into account manufacturing restraints and materials for various embodiments as recited, taught and suggested herein. The dimensions therefore are applicable to at least one embodiment but are not meant to be limiting to other embodiments of the disclosure.

FIG. 3 is a top elevational view of integral items including an article of clothing and CD/DVDs and the securing superstrate in accordance with an embodiment of the present disclosure. The block arrows depict the integration of the claimed and described components. Same reference numbers for similar limitations and/or components may be depicted in common with other figures herein.

A package system compliant with a postal service flats mail class comprises at least one flat package superstrate 50 having a uniform edge thickness about one of a longitudinal dimension 15 and a shorter dimension 20 and configured to be flexible parallel to the one dimension and adapted to receive an integral item(s) 25 parallel to the one dimension. The integral item(s) are at least one of interleaved within the superstrate 50 and received therein parallel to the one dimension and adapted to provide flexibility to the other of the two dimensions based on the interleaving and the receiving therein and provide a uniform edge thickness to the other of the two dimensions.

In some implementations, the superstrate comprises an exoskeletal rigid structure parallel to the one dimension. The exoskeletal superstructure may include a layer similar to the substrate on a topside of the superstructure and on a bottom side of the superstructure thus forming a clam shell design and other configurations. An interior superstrate thickness may be less than the uniform edge thickness as in other implementations disclosed herein.

Although the operations of the method(s) herein are shown and described in a particular order, the order of the operations of each method may be altered so that certain operations may be performed in an inverse order or so that certain operations may be performed, at least in part, concurrently with other operations. In another embodiment, instructions or sub-operations of distinct operations may be implemented in an intermittent and/or alternating manner.

While the forgoing examples are illustrative of the principles of the present disclosure in one or more particular applications, it will be apparent to those of ordinary skill in the art that numerous modifications in form, usage and details of implementation can be made without the exercise of inventive faculty, and without departing from the principles and concepts of the invention. Accordingly, it is not intended that the disclosure be limited, except as by the specification and claims set forth herein. 

What is claimed is:
 1. A postal service flats mail class package, comprising: (a) at least one flat package substrate comprising a uniform edge thickness about one of a longitudinal dimension and a shorter dimension and configured to be flexible parallel to the one dimension and adapted to receive an integral item parallel to the one dimension; (b) an integral item interleaved within the substrate parallel to the one dimension and adapted to provide flexibility to the other of the two dimensions based on the interleaving and provide a uniform edge thickness to the other of the two dimensions; and (c) a receiving package structured to receive and secure together the integral item and the flat package substrate and provide a uniform thickness and the uniform edge dimensions and be flexible about both the two dimensions to comply with a postal service flats mail class.
 2. The package of claim 1, further comprising one of a plurality of CDs (compact discs) and a plurality of DVDs (digital video disks) received in a plurality of slits in the flat package substrate configured to resemble a plurality of fish scales adapted to enable flexibility in a direction of the plurality of slits when the substrate and items are packaged.
 3. The package of claim 1, wherein the integral item wrapped around the substrate parallel to the one dimension is a textile, an article of clothing, a necklace and a bracelet.
 4. The package of claim 1, wherein the flat package substrate further comprises a scalloped edge adapted to receive one of an article of clothing, a textile, a necklace and a bracelet wrapped around the flat package substrate parallel to the one dimension.
 5. The package of claim 1, wherein an interior substrate thickness is less than the uniform edge thickness.
 6. The package of claim 1, wherein the flat package substrate is a soft cover book being most flexible about an axis parallel to the binding further comprising an external label disposed on the package oriented in a specified direction with respect to one of the flexible axis of the book along its length.
 7. The package of claim 1, further comprising a plurality of flat package substrates adapted to dispose an article there between and create thickness uniformity and edge uniformity and edge integrity resembling a clam shell design.
 8. A postal service flats mail class package, comprising: (a) at least one flat package substrate comprising a uniform edge thickness about one of a longitudinal dimension and a shorter dimension and configured to be flexible parallel to the one dimension and adapted to receive an integral item parallel to the one dimension; (b) an integral item interleaved within the substrate parallel to the one dimension and adapted to provide flexibility to the other of the two dimensions based on the interleaving and provide a uniform edge thickness to the other of the two dimensions; and (c) a soft material envelope-like sleeve structured to receive and secure together the integral item and the flat package substrate and provide a uniform thickness and the uniform edge dimensions and be flexible about both the two dimensions to comply with a postal service flats mail class.
 9. The package of claim 8, wherein the flat package substrate is a soft cover book being most flexible about an axis parallel to the binding further comprising an external label disposed on the package oriented in a specified direction with respect to one of the flexible axis of the book along its length.
 10. The package of claim 8, wherein the flat package substrate is a pharmaceutical blister pack being flexible about a first and a second dimension configured to accommodate pills.
 11. The package of claim 8, wherein the soft material comprises one of a sleeve, a sheath, a polybag, an envelope, a shrink wrapping and a vacuum packing.
 12. The package of claim 8, further comprising one of a plurality of CDs (compact discs) and a plurality of DVDs (digital video disks) received in a plurality of cutouts in the flat package substrate configured to resemble a plurality of fish scales adapted to enable flexibility in a direction of the plurality of cutouts when the substrate and items are packaged.
 13. The package of claim 8, wherein the integral item wrapped around the substrate parallel to the one dimension is a textile, an article of clothing, a necklace and a bracelet.
 14. A postal service flats mail class package system, comprising: (a) at least one flat package superstrate comprising a uniform edge thickness about one of a longitudinal dimension and a shorter dimension and configured to be flexible parallel to the one dimension and adapted to receive an integral item parallel to the one dimension; and (b) an integral item interleaved within the superstrate and received therein parallel to the one dimension and adapted to provide flexibility to the other of the two dimensions based on the interleaving and the receiving therein and provide a uniform edge thickness to the other of the two dimensions.
 15. The package of claim 14, further comprising one of a plurality of CDs (compact discs) and a plurality of DVDs (digital video disks) received in a plurality of slits in the flat package substrate configured to resemble a plurality of fish scales adapted to enable flexibility in a direction of the plurality of slits when the substrate and items are packaged.
 16. The package of claim 14, wherein the integral item received therein parallel to the one dimension is a textile, an article of clothing, a necklace and a bracelet.
 17. The package system of claim 14, wherein the superstrate comprises an exoskeletal rigid superstructure layer parallel to the one dimension configured to lend rigidity to a single superstrate and to a plurality of superstrates in a clam shell design.
 18. The package system of claim 14, wherein an interior superstrate thickness is less than the uniform edge thickness.
 19. The package system of claim 14, further comprising a receiving package structured to receive and secure together the integral item and the flat package superstrate and provide a uniform thickness and the uniform edge dimensions and be flexible about both the two dimensions for a postal service flats mail class.
 20. The package of claim 1, further comprising a plurality of flat package superstrates adapted to dispose an article there between and create thickness uniformity and edge uniformity and edge integrity resembling a clam shell design. 